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We are REALLY excited to talk paper vs. plastic!We love packaging!
(C) Dordan Manufacturing Co. Inc. 2011
2
Paper vs. Plastic
(C) Dordan Manufacturing Co. Inc. 2011
3
Paper feedstock
• The primary raw materials used for paperboard production include wood chips, residual material from softwood dimensional lumber production, and recovered paper or paperboard products.
• Additional inputs include chemicals for cooking liquors, additives such as starch and aluminum sulfate, sizing agents such as natural resins or synthetic sizing, and pigments and latex used for coatings (StoraEnso 2008).
(C) Dordan Manufacturing Co. Inc. 2011
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Pulp Conversion
• First, the wood is broken down into cellulose fibers by chemically dissolving the lignin that binds the wood fibers together (chemical pulping).
• After which, the slue is bleached, which serves to remove additional lignin from the fiber and lightens the pulp.
• Common bleaching chemicals include chlorine dioxide and to alesser degree oxygen, ozone, hydrogen peroxide and enzymes such as xylanase.
(C) Dordan Manufacturing Co. Inc. 2011
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(C) Dordan Manufacturing Co. Inc. 2011
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Paper Making
• The papermaking process begins at the wet end of the papermaking machine where a layer of furnish consisting of about 99% water and 1% pulped fiber is dispersed evenly onto a continuously moving wire screen.
• As the furnish moves through the process more and more water is removed and the paper is formed as it moves through a series of rollers.
• Once the fiber mat is established on the screen, the remainder of the process smoothes the paper through calendaring and removes water using vacuums and presses, followed by final drying.
(C) Dordan Manufacturing Co. Inc. 2011
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(C) Dordan Manufacturing Co. Inc. 2011
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Environmental Considerations
• Pulp and papermaking requires large inputs of water, energy, chemicals, and wood resources, and produces various wastes and emissions that must be controlled or treated (U.S. DOE 2005).
• Impacts on the environment can come from toxic and hazardous chemicals in air and water emissions, thermal and wastewater loading to natural waterways, odor–causing chemicals, air pollutants from combustion, and solid wastes (U.S. DOE 2005).
(C) Dordan Manufacturing Co. Inc. 2011
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Monomer Production Process
• Both natural gas and petroleum are extracted from the earth for the production of plastic.
• After extraction, these materials are transported to a gas processing plant or oil refinery where they are mixed with naphtha prior to the steam cracking process.
• The extreme heat used in the process reduces or ‘cracks’ the molecule size of the natural gas or oil, forming lighter and more reactive hydrocarbons like ethylene and other monomers such as propylene.
(C) Dordan Manufacturing Co. Inc. 2011
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Polymer Production Process, Ex: PP
• PP is typically formed in either liquid or gas phase propylene reactions.
• Liquid propylene polymerization is carried out at pressure of about 365-510 psi and a temperature of 140-175 F. The process requires a reactor for the propylene monomer, hydrogen, and catalyst.
• As the propylene monomer flows through the reactor, about 50% of it reacts and becomes polypropylene polymer.
• The unreacted propylene is recycled back to the reactor. The polypropylene polymer is fed into a pelletizer to form pellets.
(C) Dordan Manufacturing Co. Inc. 2011
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(C) Dordan Manufacturing Co. Inc. 2011
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Environmental Considerations
• Oil and natural gas are the primary sources of energy for resin production; however, 10-15% of energy required for resin production is embedded in the polymer available for later recovery.
• Carbon dioxide, methane and nitrous oxide are the major greenhouse gases emitted during resin production; however, over 75% of C02 emissions are related to fossil fuel use (Franklin 2007).
(C) Dordan Manufacturing Co. Inc. 2011
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HDPE LDPE LLDPE PP PET GPPS HIPS PVC ABS Fiber-Based Packaging Materials
0
2
4
6
8
10
12
14
16
Energy Required for Production of Common Packaging Polymers and Fiber-Based Packaging Materials (Franklin Associates, a Division of ERG, 2007 & U.S. DOE, 2005)
Material Type
Mil
lio
n B
tu p
er 1
,000
lb
s o
f m
ater
ial
pro
du
ced
(C) Dordan Manufacturing Co. Inc. 2011
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PET HDPE PVC LDPE PP PS PLA0
500
1000
1500
2000
2500
3000
Overall Emissions/Waste Generated in Polymer Production(Franklin 2007. Brown and Cole 1993, APME 2005/6 & NAPCOR 2006)
Air Emissions
Water Discharges
Solid Waste
Polymer Type
Lb
s o
f w
aste
gen
erat
ed p
er 1
,000
lb
s o
f re
sin
pro
du
ced
(C) Dordan Manufacturing Co. Inc. 2011
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Mult
iple
within
SIC C
ode
26*
Paper
boar
d M
ills
Paper
Mills
Pulp M
ills
Paper
Coa
ted
& Lam
inate
d, n
ec*
Paper
Coa
ted
and
Lam
inate
d, P
acka
ging
Folding
Pap
erbo
ard
Boxes
Conve
rted
Paper
Pro
duct
s, n
ec*
Sanita
ry F
ood
Conta
iners
Bags:
Plas
tic, L
amina
ted,
& C
oate
d
Fiber C
ans,
Dru
ms
& Sim
ilar P
rodu
cts
Bags:
Unc
oate
d Pap
er &
Mult
iwall
Corru
gate
d & S
olid
Fiber B
oxes
Sanita
ry P
aper
Pro
duct
s0
10,000,000
20,000,000
30,000,000
40,000,000
50,000,000
60,000,000
70,000,000
80,000,000
90,000,000
100,000,000
TRI Data: Pulp and Paper Production Air Emissions and Surface Water Discharges(U.S. EPA 1996)
Total Air Emissions
Surface Water Discharges
Industry
Lb
s o
f E
mis
sio
ns/
Dis
char
ges
(C) Dordan Manufacturing Co. Inc. 2011
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Container and Packaging MSW Data, 2007 (U.S. EPA 2008)
Paper & Paperboard
52%
Plastic
17%
Glass
15%
Wood
11%
Steel
3%
Aluminum
2%
Paper & Paperboard
Plastic
Glass
Wood
Steel
Aluminum
(C) Dordan Manufacturing Co. Inc. 2011
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Container and Packaging % Recovery, (US EPA 2008)
(C) Dordan Manufacturing Co. Inc. 2011
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Paper vs. Plastic COMPASS LCACS-002 plastic: 36.854 g of Polyethylene Terephthalate (PET) converted using Thermoforming with Calendering
CS-002 corrugated: 96.544 g of Corrugated converted using Production of Corrugated Container
(C) Dordan Manufacturing Co. Inc. 2011
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High-five to you!!!For taking the time to learn about paper and plastic!